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Takata adds millions to recall expansion in US [UPDATE]

UPDATE: Ford spokesperson Kelli Felker has advised Autoblog that of the 1,509,535 total vehicles worldwide that the company is recalling, 966,504 of them are new additions for this expanded safety campaign. Last week, the National Highway Traffic Safety Administration announced that the Takata airbag inflator recalls would expand to an estimated 33.8 million vehicles in the US. However at the time, automakers weren't sure specifically which of their models might be affected under this enlarged campaign. Now, the numbers for BMW, FCA, Ford, and Mitsubishi are being released by the agency. Additionally, Honda is outlining the broadening of its own campaign. BMW's recall amounts to 420,661 vehicles in the US, an increase from 140,696 previously. All of the following models need their front, driver's side airbag replaced: 2002-2005 BMW 325i/325xi/330i/330xi Sedan 2002-2005 BMW 325xi/325i Sportswagon 2002-2006 BMW 330Ci/325Ci/M3 Convertible 2002-2006 BMW 325i/330i/M3 Coupe 2002-2003 BMW M5/540i/525i/530i Sedan 2002-2003 BMW 540i/525i Sportswagon 2003-2004 BMW X5 3.0i/4.4i BMW has received no reports of any injures or deaths from this problem in its vehicles. FCA has 5,224,845 vehicles globally in need of inflator replacements, according to its statement. However, the company is only aware of one injury related to the issue, which occurred in a 2006 Dodge Charger in southern Florida. There are 4,747,202 vehicles worldwide from the company that are affected on the front, driver's side. Among these, 4,066,732 are in the US, 374,508 are in Canada, and the rest are in other countries. The models are: 2005-2009 Dodge Ram 2500 Pickup 2004-2008 Dodge Ram 1500 Pickup 2006-2009 Dodge Ram 3500 Pickup 2007-2009 Dodge Ram 3500 Cab Chassis 2008-2010 Dodge Ram 4500/5500 Cab Chassis 2008-2009 Sterling 4500/5500 Cab Chassis 2004-2008 Dodge Durango 2007-2008 Chrysler Aspen 2005-2010 Chrysler 300/300C/SRT8 2005-2010 Dodge Charger/Magnum 2005-2011 Dodge Dakota 2006-2010 Mitsubishi Raider Also, there are 438,156 vehicles in the US, according to the NHTSA documents, that need their front passenger's side inflators replaced in the expansion of an earlier regional recall: 2003 Dodge Ram 1500 2003 Dodge Ram 2500 2003 Dodge Ram 3500 The total number of vehicles from Ford now covered under these campaigns stands at 1,509,535 worldwide. Of this total, there are 1,380,604 in the United States, 93,207 in Canada and 16,953 in Mexico.

Ford reveals new rapid prototyping and low-volume production techniques [w/video]

It's called "F3T," and that stands for Ford Free-form Fabrication Technology. The process that The Blue Oval has developed means being able to sidestep the weeks-long process of tool-and-die making when engineers want to construct a new part, allowing them to fabricate a three-dimensional part from a two-dimensional sheet of metal in just hours.
While F3T is being developed it is limited to "low-volume prototyping or even low-volume niche vehicles," but the next step is to evaluate it for use in Ford's global manufacturing facilities. You can find out more about it in the video and the press release below.

Ford settles class action suit over defective Navistar diesel engines

The 2003 Ford F-Series Super Duty (shown above) introduced the 6.0-liter Power Stroke diesel supplied by Navistar, and while that is an engine Ford would love to forget, it's now one step closer to putting that particular problem behind it. Automotive News is reporting that Ford has settled a class-action lawsuit brought on by problems with this engine that started right out of the gate and ultimately broke up the 30-year relationship between Ford and Navistar.
Owners and lessees of 2003-2007 Super Duty trucks and E-Series vans equipped with the 6.0-liter Power Stroke are eligible for deductible reimbursements of between $50 and $200 from the original five-year/100,000-mile engine warranty, while Ford is paying out as much as $825 for out-of-warranty engine repairs. These repairs may include the exhaust gas recirculation (EGR) cooler, EGR valve, oil cooler, fuel injectors and turbocharger, but are only covered if the components failed before six years or 135,000 miles.
In total, Ford has agreed to pay about 50 percent of the value of the repairs and deductibles paid by its customers who submit a claim before the end of this year, and $150,000 is going to the 16 named plaintiffs in the case; Navistar was not included in the lawsuit.